Update: 3D Printed Concrete Castle Completed

Concrete Castle

After two years of dreaming, designing, and doing, [Andrey Rudenko] has finally finished 3D printing his concrete castle. We’re sure a few readers will race to the comments to criticize the use of “castle” as an acceptable descriptor, but they’d be missing the point. It’s been only three months since he was testing the thing out in his garage, and now there’s a beautiful, freestanding structure in his yard, custom-printed.

There are no action shots of the printer setup as it lays down fat beads of concrete, only close-ups of the nozzle, but the castle was printed on-site outdoors. It wasn’t, however, printed in one piece. [Andrey] churned out the turrets separately and attached them later. He won’t be doing that again, though, because moving them in place was quite the burden. On his webpage, [Andrey] shares some insight in a wrap-up of the construction process. After much experimentation, he settled on a layer height of 10mm with a 30mm width for best results. He also discovered that he could print much more than his original estimation of 50cm of vertical height a day (fearing the lower layers would buckle).

With the castle a success, [Andrey] plans to expand his website to include a “posting wall for new ideas and findings.” We’re not sure whether that statement suggests that he would provide open-source access to everything or just feature updates of his future projects.

Wooden supports for concrete bridging.

[Andrey] used wooden supports to print concrete bridges.

We hope the former. You can check out its current format as the Architecture Forum, where he explains some of the construction capabilities and tricks used to build the castle.

His next project, a full-scale livable structure, will attempt to print 24/7 (weather permitting) rather than the stop-start routine used for the castle, which turned out to be the culprit behind imperfections in the print. He’ll have to hurry, though. [Andrey] lives in Minnesota, and the climate will soon cause construction to take a 6-month hiatus until warm weather returns. Be sure to check out his website for more photos and a retrospective on the castle project, as well as contact information—[Andrey] is reaching out to interested parties with the appropriate skills (and investors) who may want to help with the new project.

[via 3ders.org]

[Thanks Brian]

THP Semifinalist: The Medicycle

4029151407876710508Despite a seeming lack of transportation projects for The Hackaday Prize, there are a few that made it through the great culling and into the semifinalist round. [Nick], [XenonJohn], and [DaveW]‘s project is the Medicycle. It’s a vehicle that will turn heads for sure, but the guys have better things in mind than looking cool on the road. He thinks this two-tire unicycle will be useful in dispatching EMTs and other first responders, weaving in and out of traffic to get where they’re needed quickly.

First things first. The one-wheeled motorcycle actually works. It’s basically the same as a self-balancing scooter; the rider leans forward to go forward, leans back to break, and the two tires help with steering. It’s all electronic, powered by a 450W motor. It can dash around alleys, parking lots, and even gravel roadways.

The medi~ part of this cycle comes from a mobile triage unit tucked under the nose of the bike. There are sensors for measuring blood pressure and oxygen, heart rate, and ECG. This data is sent to the Medicycle rider via a monocular display tucked into the helmet and relayed via a 3G module to a physician offsite.

Whether the Medicycle will be useful to medics remains to be seen, but the guys have created an interesting means of transportation that is at least as cool as a jet ski. That’s impressive, and the total build cost of this bike itself is pretty low.

Video of the Medicycle in action below.

SpaceWrencherThe project featured in this post is a semifinalist in The Hackaday Prize.
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Hydropower from a Washing Mashine

Hydropower Washing Machine

Living off the grid is an appealing goal for many in the hacker community, perhaps because it can fulfill the need to create, to establish independence, to prepare for the apocalypse, or some combination of all those things. [Buddhanz1] has been living off the grid for awhile now by harnessing power from a nearby stream with an old washing-machine-turned-generator.

He started with a Fisher & Paykel smart drive, which he stripped down to the middle housing, retaining the plastic tub, the stator, the rotor, the shaft, and the bearings. After a quick spot check to ensure the relative quality of the stator and the rotor, [Buddhanz1] removed the stator and rewired it. Unchanged, the stator would output 0-400V unloaded at 3-4 amps max, which isn’t a particularly useful range for charging batteries. By rewiring the stator (demonstration video here) he lowered the voltage while increasing the current.

The key to this build is the inclusion of a pelton wheel—which we’ve seen before in a similar build. [Buddhanz1] channeled the water flow directly into the pelton wheel to spin the shaft inside the tub. After adding some silicon sealant and an access/repair hatch, [Buddhanz1] painted the outside to protect the assembly from the sun, and fitted a DC rectifier that converts the electricity for the batteries. With the water pressure at about 45psi, the generator is capable of ~29V/21A: just over 600W. With a larger water jet, the rig can reach 900W. Stick around for the video after the break.

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Extrinsic Motivation: Smart Antenna Tracker for R/C Aircraft


Long distance FPV (First Person View) flying can be a handful. Keeping a video feed alive generally requires a high gain directional antenna. Going directional creates the chore of keeping the antenna pointed at the aircraft. [Brandon's] smart antenna tracker is designed to do all that automatically. What witchcraft is this, you ask? The answer is actually quite simple: Telemetry! Many flight control systems have an optional telemetry transmitter. [Brandon] is using the 3DRobotics APM or PixHawk systems, which use 3DR’s 915 MHz radios.

The airborne radio sends telemetry data, including aircraft latitude and longitude down to a ground station. Equipped with a receiver for this data and a GPS of its own, the smart antenna tracker knows the exact position, heading and velocity of the aircraft. Using a pan and tilt mount, the smart antenna tracker can then point the antenna directly at the airborne system. Since the FPV antenna is co-located on the pan tilt mount, it will also point at the aircraft and maintain a good video link.

One of the gotchas with a system like this is dealing with an aircraft that is flying directly overhead. The plane or rotorcraft can fly by faster than the antenna system can move. There are a few commercial systems out there that handle this by switching to a lower gain omnidirectional whip antenna when the aircraft is close in. This would be a great addition to [Brandon's] design.

A Peach of a Homemade Parts Tumbler

tumbler[Chris] finds the average price of rock tumblers insulting. Almost as insulting, in fact, as prepackaged fruit salad made with Chinese peaches. While there may be little he can do about the peaches, he has given the finger to lapidary pricing by making his own tumbler on the very cheap.

Simply put, he drilled a hole in bottom of the peach vessel and then stuck a threaded rod through it. He held the rod in place with a nut and a washer. After securing the proper permits to source sand and water from his property, he put both in the jar along with some old nails that had paint and crud on them. [Chris] put the rod in the chuck of his drill and clamped the drill in his bench vise. Half an hour later, he had some nice, shiny nails. Make the jump to be amazed and entertained. If you prefer using balls, check out this homemade mill.

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Hackaday Retro Edition: 386 Compaqs

compaq [Antoine] recently learned of a little challenge we have in the hinterlands of the Hackaday webosphere – what’s the oldest, or lowest spec hardware you have that can load this our retro edition? He has a pile of old PCs at his work, and with a lot of idle time at work because of summer, he decided to dig into that pile and get a really old computer up on the Internet.

While the pile of PCs didn’t have anything as old as he was expecting, [Antoine] did find an old Compaq from 1992. It has a 386DX running at 25MHz, 4MB of RAM, a 300 MB hard drive, VGA, and an Ethernet NIC. Gathering the requisite CRT monitor, PS/2 keyboard, and an AUI to a more modern Ethernet connector.

When getting these ancient computer on the Internet, the secret sauce is in the software configuration. [Antoine]‘s box is running DOS 6.2, but was previously configured to connect to a Microsoft filesystem server on boot. This server was probably somewhere at the bottom of the same pile the Compaq was salvaged from, so rolling his own modern networking stack was the way to go. A driver for the NIC was downloaded on another computer and transferred via floppy, as was mTCP, the key to getting a lot of old PCs on the Internet. The browser is Arachne, and with the right configurations, everything worked perfectly.

[Antoine]‘s efforts resulted in a computer that can easily handle the stripped down Hackaday retro edition, and can handle light browsing on Wikipedia. The effective download rate is something like a 33k modem; even with a fast (10M!) Ethernet connection, processing all the packets is taxing for this old machine.

Arduino-based LED Wedding Lights

Light (1 of 3)Light (2 of 3)

[Rob] created these amazing Bluetooth controlled LED lights for his daughter’s wedding adding a colorful ambient glow to the ceremony. Each item held a Neopixel ring and an Arduino microprocessor with a wireless module that could be individually addressed over a ‘mini-network.’ The main master station would receive commands from a Windows Phone. Usually we see Arduino-based projects being run with Android apps, so it’s nice to see that Microsoft is still present in the maker community.

The enclosures and translucent vases that sit atop the devices were 3D printed. All eight of the matrimonial units synchronized with each other, and the colors could be changed by sliding the settings bar on the app.  [Rob] says that it was a lot of fun to build, and jokingly stated that it kept him “out of all the less important aspects of the ceremony. (food choice, decor, venue, who to marry etc etc).” The outcome was a beautiful arrangement of tabletop lighting for the wedding. A demo of [Rob]‘s setup can be seen in the video below.

[Read more...]


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